Double-sided starter/generator for aircrafts

ABSTRACT

An electromagnetic machine for extracting power from a turbine engine includes an outer rotor and an inner rotor rotatably supported adjacent to a stator. The stator is disposed between the inner and outer rotors. The stator has an inner set of windings disposed on an inner surface adjacent to the inner rotor, and an outer set of windings on an outer surface of the stator adjacent to the outer rotor. A plurality of permanent magnets are disposed on an inner surface of the outer rotor element and on an outer surface of the inner rotor element. Air gaps are defined between the outer surface of the stator and the outer permanent magnets, and between the inner surface of the stator portion and the inner permanent magnets. The inner stator windings form a set of multiple-phase windings, and the outer stator windings form a set of multiple-phase windings.

FIELD OF THE INVENTION

The present invention is directed to an electrical machine for aircrafts, and more particularly to an electrical motor/generator having coaxial dual rotors independently driven by a high- and low-pressure turbine shaft, respectively, of a gas turbine engine.

BACKGROUND OF THE INVENTION

A gas turbine engine generally includes one or more compressors followed in turn by a combustor and high and low pressure turbines. These engine components are arranged in serial flow communication and disposed about a longitudinal axis centerline of the engine within an annular outer casing. The compressors are driven by the respective turbines and compressor air during operation. The compressor air is mixed with fuel and ignited in the combustor for generating hot combustion gases. The combustion gases flow through the high and low pressure turbines, which extract the energy generated by the hot combustion gases for driving the compressors, and for producing auxiliary output power.

The engine power is transferred either as shaft power or thrust for powering an aircraft in flight. For example, in other rotatable loads, such as a fan rotor in a by-pass turbofan engine, or propellers in a gas turbine propeller engine, power is extracted from the high and low pressure turbines for driving the respective fan rotor and the propellers.

It is well understood that individual components of turbofan engines, in operation, require different power parameters. For example, the fan rotational speed is limited to a degree by the tip velocity and, since the fan diameter is very large, rotational speed must be very low. The core compressor, on the other hand, because of its much smaller tip diameter, can be driven at a higher rotational speed. Therefore, separate high and low turbines with independent power transmitting devices are necessary for the fan and core compressor in aircraft gas turbine engines. Furthermore since a turbine is most efficient at higher rotational speeds, the lower speed turbine driving the fan requires additional stages to extract the necessary power.

Many new aircraft systems are designed to accommodate electrical loads that are greater than those on current aircraft systems. The electrical system specifications of commercial airliner designs currently being developed may demand up to twice the electrical power of current commercial airliners. This increased electrical power demand must be derived from mechanical power extracted from the engines that power the aircraft. When operating an aircraft engine at relatively low power levels, e.g., while idly descending from altitude, extracting this additional electrical power from the engine mechanical power may reduce the ability to operate the engine properly.

Traditionally, electrical power is extracted from the high-pressure (HP) engine spool in a gas turbine engine. The relatively high operating speed of the HP engine spool makes it an ideal source of mechanical power to drive the electrical generators connected to the engine. However, it is desirable to draw power from additional sources within the engine, rather than rely solely on the HP engine spool to drive the electrical generators. The LP engine spool provides an alternate source of power transfer, however, the relatively lower speed of the LP engine spool typically requires the use of a gearbox, as slow-speed electrical generators are often larger than similarly rated electrical generators operating at higher speeds. The boost cavity of gas turbine engines has available space that is capable of housing an inside out electric generator, however, the boost section rotates at the speed of the LP engine spool.

However, extracting this additional mechanical power from an engine when it is operating at relatively low power levels (e.g., at or near idle descending from altitude, low power for taxi, etc.) may lead to reduced engine operability. Traditionally, this power is extracted from the high-pressure (HP) engine spool. Its relatively high operating speed makes it an ideal source for mechanical power to drive electrical generators that are attached to the engine. However, it is desirable at times to increase the amount of power that is available on this spool, by transferring torque and power to it via some other means.

Another source of power within the engine is the low-pressure (LP) spool, which typically operates at speeds much slower than the HP spool, and over a relatively wider speed range. Tapping this low-speed mechanical power source without transformation result in impractically large generators.

Many solutions to this transformation are possible, including various types of conventional transmissions, mechanical gearing, and electromechanical configurations.

One solution is a turbine engine that utilizes a third, intermediate-pressure (IP) spool to drive a generator independently. However, this third spool is also required at times to couple to the HP spool. The means used to couple the IP and HP spools are mechanical clutch or viscous-type coupling mechanisms.

U.S. patent No. U.S. Pat. No. 6,895,741, issued May 24, 2005, and entitled “Differential Geared Turbine Engine with Torque Modulation Capacity”, discloses a mechanically geared engine having three shafts. The fan, compressor, and turbine shafts are mechanically coupled by applying additional epicyclic gear arrangements. The effective gear ratio is variable through the use of electromagnetic machines and power conversion equipment.

U.S. Pat. No. 6,924,574 discloses a dual-rotor, radial-flux, toroidally-wound, permanent-magnet machine having improved electrical machine torque density and efficiency. At least one concentric surface-mounted permanent magnet dual-rotor is located inside and outside of a torus-shaped stator with back-to-back windings, respectively. The permanent magnet machine includes at least one permanent magnet rotor having a generally cylindrical shape with an inner rotor component and an outer rotor component, and at least one stator having a hollow cylindrical shape positioned within an opening between the inner and outer components of the permanent magnet rotor. A plurality of polyphase windings of electrical wires are wound around the at least one stator.

Therefore, there is a need for a gas turbine engine with a compact motor/generator that is capable of generating electric power from both the LP and HP engine spools.

SUMMARY OF THE INVENTION

The present invention is directed to a double-sided dual-shaft (DSDS) electrical machine having a rotor connected to the HP spool and a rotor connected to the LP spool. A stator portion is disposed between the two rotors. The DSDS electrical machine is configured to generate electric power from either or both rotors. The inner and outer rotor shafts of the DSDS machine are independently driven by HP and LP shafts, respectively. The independent rotor shafts permit each rotor to rotate at different speeds, and to operate one side of the machine as a generator, and the opposing side of the electrical machine as a motor, using power electronic converters. The stator includes a pair of opposing windings. Each opposing set of stator windings is adjacent to a respective rotor, and separated from the associated rotor by an air gap. Thus, the speed and the direction of rotation of each rotor shaft is independent of the other.

An advantage of the present invention is that both the HP and LP spools can be connected to the single compact generator having less mass and volume compared to two separate electric machines.

Another advantage is that electrical power can be drawn form either or both sides of the motor/generator.

A further advantage of the present invention is that it incorporates all features from a double-sided structure motor/generator, including reduced radial force on the stator, reduced stator yoke thickness, reduced frame mass and lower cost of construction.

Yet another advantage of the present invention is that partial load can be sustained during some fault conditions, providing greater reliability.

Another advantage is that HP and LP generator sections may be individually optimized for speed range and power output in relation to number of poles.

Another advantage of the present invention is greatly reduced cost by providing the capability of using a larger power rating machine instead of two smaller machines, consuming smaller volume on the aircraft and making direct drive possible for some applications.

Other features and advantages of the present invention will be apparent from the following more detailed description of the preferred embodiment, taken in conjunction with the accompanying drawings which illustrate, by way of example, the principles of the invention.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a longitudinal sectional view schematic illustration of an exemplary aircraft turbofan gas turbine engine.

FIG. 2 is a partial axial cross-sectional view of the double-sided electrical machine of the present invention.

FIG. 3 is a partial cross-sectional view of the double-sided electrical machine of the present invention.

FIG. 4 is a partial cross-sectional schematic illustration of the double-sided electrical machine of the present invention with different number of phases for inner and outer portions.

FIG. 5 is a schematic representation of one exemplary interconnection between the double-sided machine and power converter.

FIG. 6 is a schematic representation of another exemplary interconnection between the double-sided machine and power converter.

FIG. 7 is a schematic representation of a double-sided electric machine of the present invention connected to Low Pressure and High Pressure spools.

Wherever possible, the same reference numbers will be used throughout the drawings to refer to the same or like parts.

DETAILED DESCRIPTION OF THE INVENTION

Illustrated in FIG. 1 is an exemplary turbofan engine 10 having a generally axially extending axis or centerline 12 generally extending in a forward direction 14 and an aft direction 16. The bypass turbofan engine 10 includes a core engine 18 (also called a gas generator) which includes a high pressure compressor 20, a combustor 22, and a high pressure turbine (HPT) 23 having a row of high pressure turbine blades 24, all arranged in a serial, axial flow relationship. High-pressure compressor blades 64 of the high-pressure compressor 20 are fixedly connected in driving engagement to the high pressure turbine blades 24 by a larger-diameter annular core engine shaft 26 which is disposed coaxially about the centerline 12 of the engine 10 forming a high pressure spool 21.

A combustor 22 in the core engine 18 mixes pressurized air from the high-pressure compressor 20 with fuel and ignites the resulting fuel and air mixture to produce combustion gases. Some work is extracted from these gases by the high-pressure turbine blades 24 which drives the high pressure compressor 20. The combustion gases are discharged from the core engine 18 into a power turbine or low-pressure turbine (LPT) 27 having a row of low pressure turbine blades 28. The low-pressure turbine blades 28 are fixedly attached to a smaller diameter annular low-pressure shaft 30 which is disposed coaxially about the centerline 12 of the engine 10 within the core engine shaft 26 forming a low pressure spool 29. The low pressure shaft 30 rotates axially spaced-apart first and second stage fans 31 and 33 of an engine fan section 35. The first and second stage fans 31 and 33 include first and second stage rows of generally radially outwardly extending and circumferentially spaced-apart first and second stage fan blades 32 and 36, respectively.

A fan bypass duct 40 circumscribes the second stage fan 33 and the core engine 18. Core discharge airflow 170 is discharged from the low pressure turbine 27 to mix with a bypass airflow 178 discharged from the fan bypass duct 40 through a rear variable area bypass injector (VABI) 53. Mixing takes place in a tail pipe 69 in which exhaust flow is formed which is discharged through a variable area exhaust nozzle. An optional afterburner 130 may be used to increase the thrust potential of the engine 10.

Referring to FIG. 2, a double-sided, dual-shaft (DSDS) electric machine is generally designated as 100. The inner and outer rotors 72, 76, are independent and rotatable at different velocity. Each rotor 72, 76 has at least one bearing 73, 77 for each shaft 30, 26, respectively. The bearing position and type may vary based on application requirements.

Referring next to FIGS. 2 and 3, the turbine engine 10 includes a DSDS machine 100 comprising an outer rotor core 76 and an inner rotor core 72, which are generally hollow cylindrical components with a stator portion 66 disposed concentrically between the inner and outer rotor cores 72, 76 about the axis 12. Opposing frame sections 56, 58 provide rigid support for stator portion 66 inside the engine 10, and include central openings for bearings 73, 77, for rotatably supporting the LP shaft 30 and the HP shaft 26. An inner set of stator windings 67 are mounted on the radially inner surface of the stator portion 66. Inner stator windings 67 are interconnected to form a first set of multiple-phase windings 88 (see, e.g., FIGS. 5 & 6). An outer set of stator windings 65 are mounted on the radially outer surface of the stator portion 66. Outer stator windings 65 are interconnected to form a second set of multiple-phase windings 89 (see, e.g., FIGS. 5 & 6). The outer rotor core 76 has outer permanent magnets 75 and an inner rotor core 72 with inner permanent magnets 74. The stator portion 66 has outer tooth portions 104 and inner tooth portions 106, which are separated by slots 80, 84. The outer stator windings or coils 65 and the inner stator windings or coils 67 are retained in slots 80, 84, respectively by the outer stator coil retaining wedge 108 and inner stator coil retaining wedge 110. An outer air gap 62 is defined between the double-sided stator portion 66 and the permanent magnets 75 attached to the outer rotor 76, and an inner air gap 64 is defined between the stator portion 66 and the permanent magnets 74 attached to the inner rotor 72. In the embodiment, shown in FIG. 3, the stator portion 66 is structurally reinforced through compression of a lamination stack by a plurality of circumferentially spaced bolts 68 arranged parallel with the axis 12 in the stator yoke portion 116. The bolt shafts 70 and at least one bolt end 68 are insulated from the laminations and frame structures by insulator tubes 71 and insulator rings 79 to avoid induced electrical currents and resulting losses and heating. In the example shown in FIG. 3, one bolt per slot is used and the bolthole positions are aligned with stator teeth 104, 106, e.g., with boltholes 69, however, more or less bolts may be used, as will be appreciated by those skilled in the art. Also illustrated are air cavity 112 between outer stator windings 65 and the air cavity 114 between the inner stator windings 67 for air-cooling the windings 65, 67.

The stator windings 65, 67 disposed in the slots 80, 84 defined between pairs of tooth portions 104, 106, are arranged side-by-side in FIG. 3. The windings 65, 67 are preferably toroidally-wound around the stator tooth portions 104, 106. These windings may also be arranged in top and bottom layers, or as a single coil per slot 80, 84. The inner coils 67 are interconnected to form one set of multiple-phase windings, and the outer coils 65 are interconnected to form a second set of multiple-phase windings. A converter 90 (see, e.g., FIGS. 5 and 6) is connected to drive each set of windings, respectively, so that each set of windings can be operated independently. Therefore, in general, the HP and LP shafts 30, 26 can rotate concurrently in the same or in opposite directions, and may be controlled for operation at matching velocity or at separate and distinct velocities.

The poles 74, 75 in this exemplary embodiment are surface-mounted permanent magnet poles. Alternatively, interior permanent magnet poles, wound-field poles, reluctance rotor poles, cage or wound induction type poles, etc. may be used in place of the permanent magnet poles for either or both rotors 72, 76. The numbers of pole, slots, and phases for the inner and outer machines may vary, depending on the particular electrical power requirements. Further, the two sides can be configured and optimized independently.

Reliability and fault tolerance is important for all electrical machines used in an aircraft. According to the present invention, the multiple-phase windings from either the inner rotor portion 72 or the outer rotor portion 76 can be separated into multiple sets, wherein each set of phase(s) is driven by an individual converter 90. Thus, in case of failure of a converter 90 or a machine winding 65, 67, only one set of phase(s) is rendered inoperable, while the remaining phases remain operable to provide power to the aircraft.

Referring to FIG. 4, an exemplary embodiment of the present invention whereby inner and outer stator windings 67, 65 are configured in independent multi-phase generators. The outer set of windings 65 are arranged in six phases of multi-phase windings 65 designated as A₁ through F₁. Permanent magnets 75 alternate in polarity between north (N) and south (S), which induce electromagnetic energy in windings A₁ through F₁ as the magnets 75 are rotated on outer rotor 76 past the windings A₁ through F₁ to form a magnetic flux path with the stator tooth portions 104 across air gap 62. The inner stator tooth portions 67 are arranged in this example into three phases of multi-phase windings A₂ through C₂, which are independent of phase windings A₁ through F₁. Permanent magnet 74 provides the sole source of excitation of all three of phase windings A₂ through C₂ associated with the inner stator windings 67, as the magnets 74 are rotated on inner rotor 72 past the windings A₂ through C₂ to form a magnetic flux path with the stator tooth portions 106 across air gap 64.

Referring to FIGS. 5 & 6, each set of multiple-phase windings 88 are driven by a converter 90, to permit each set of windings 88 to operate independently of the other. Therefore, shafts 26, 30 can concurrently rotate (a) in opposite directions, (b) in the same direction at different velocity, or (c) in the same direction and at the same velocity.

FIGS. 5 & 6 are exemplary implementations wherein multiple-phase windings 88 are separated into multiple sets. In FIG. 5, there are two sets 88 of phase windings—a first set of phase windings 86 configured with N1 phases, and a second set of phase windings 89 configured with N2 phases. Each phases winding set 86, 89 is driven by an individual converter 90. In an alternate embodiment, shown in FIG. 6, 3-phase windings 88 are each driven by individual, dedicated converter units 90.

FIG. 7 illustrates an embodiment of the double-sided electrical machine 100 in an aircraft engine. The DSDS machine 100 is connected to both the LP spool 30 and HP spool 26, to generate electric power and, in some instances, to start the HP spool 26. The LP spool 26 is connected to the inner rotor 72 through a gearbox 92. The gearbox 92 may be either a mechanical gearbox or a magnetic gearbox. The outer rotor 76 is connected to the HP spool 30 through another gearbox 94 that may likewise be a mechanical or magnetic device. The DSDS machine 100 can extract mechanical power from either inner rotor 72 or the outer rotor 76 into electric power as needed. The relative amount of electric power extracted from the HP or LP turbines through either shaft 26, 30 is fully controllable through the converter 90 and the machine is designed accordingly. The gearboxes 92, 94 on the both sides are optional, and either or both gearboxes can be removed depending on the system design parameters. Also, depending on the torque level and maximum velocity of the DSDS machine 100, the HP shaft 30 may be connected to the inner rotor and the LP shaft 26 connected to the outer rotor.

While the double-sided machine has been generally described as two generator configurations, it will be appreciated by those practitioners skilled in the art of electric machines that the DSDS machine may operate as a starter motor for the turbine engine 10 by energizing either set of inner or outer windings 65, 67, thus inducing rotation in one of the rotor portions 72, 76. Preferably, the rotor connected to the HP turbine shaft is used as a starting motor, although either rotor may be operable as a starting motor to start the engine 10.

While the invention has been described with reference to a preferred embodiment, it will be understood by those skilled in the art that various changes may be made and equivalents may be substituted for elements thereof without departing from the scope of the invention. In addition, many modifications may be made to adapt a particular situation or material to the teachings of the invention without departing from the essential scope thereof. Therefore, it is intended that the invention not be limited to the particular embodiment disclosed as the best mode contemplated for carrying out this invention, but that the invention will include all embodiments falling within the scope of the appended claims. 

1. An electromagnetic machine for extracting electrical power from a gas turbine engine comprising: an outer rotor element and an inner rotor element rotatably supported adjacent to a fixed stator portion, the stator portion disposed concentrically between the inner and outer rotor elements about a central axis; opposing frame portions connected at a first end and a second end of the stator portion to support the stator portion within the gas turbine engine; the stator portion having an inner set of stator windings disposed on a radially inner surface of the stator portion adjacent to the inner rotor, and an outer set of stator windings disposed on a radially outer surface of the stator portion adjacent to the outer rotor; the inner rotor element driven by a first turbine shaft and the outer rotor element driven by a second turbine shaft of the gas turbine engine, each of the first turbine shaft and the second turbine shaft independently rotatable with respect to the other of the first turbine shaft and the second turbine shaft, the first turbine shaft and the second turbine shaft concurrently rotatable in the same or in opposite directions and controllably operable at matching velocity or at separate and distinct velocities; a plurality of outer permanent magnets disposed on an inner surface of the outer rotor element and a plurality of inner permanent magnets disposed on an outer surface of the inner rotor element; an outer air gap defined between the outer surface of the stator portion and the outer permanent magnets, and an inner air gap defined between the inner surface of the stator portion and the inner permanent magnets; the inner stator windings electrically interconnected to form a first set of multiple-phase windings and the outer stator windings electrically interconnected to form a second set of multiple-phase windings for powering an electrical load.
 2. The electromagnetic machine of claim 1, wherein the stator windings disposed in slots defined between pairs of tooth portions.
 3. The electromagnetic machine of claim 1, wherein the inner and outer stator windings are arranged side-by-side within the slots.
 4. The electromagnetic machine of claim 1, wherein the inner and outer stator windings are toroidally-wound around the stator tooth portions.
 5. The electromagnetic machine of claim 1, wherein the inner and outer stator windings are arranged at least one layer.
 6. The electromagnetic machine of claim 1, wherein the inner and outer stator windings are arranged one winder to a slot.
 7. The electromagnetic machine of claim 1, wherein the inner stator windings are interconnected to form one set of multiple-phase windings, and the outer stator windings are interconnected to form a second set of multiple-phase windings.
 8. The electromagnetic machine of claim 1, also comprising: a plurality of converters, each of the converters connected to a set of windings to independently drive the associated phase winding.
 9. The electromagnetic machine of claim 1, wherein the first turbine shaft is connected to a high pressure (HP) turbine and the second turbine shaft is connected to a low pressure (LP) turbine.
 10. The electromagnetic machine of claim 1, wherein the opposing frame portions include axial openings at opposing ends of the machine, and at least two bearings for rotatably supporting the LP shaft and the HP shaft connected to the inner and outer rotor elements.
 11. The electromagnetic machine of claim 1, wherein the stator portion includes a plurality of outer tooth portions defining a first set of slots therebetween, and a plurality of inner tooth portions defining a second set of slots therebetween, the outer stator windings retentively positioned within the first set of slots and the inner stator windings retentively positioned within the second set of slots.
 12. The electromagnetic machine of claim 1, wherein the stator portion further comprising a lamination stack structurally reinforced through compression by a plurality of circumferentially spaced bolts arranged parallel with the axis in a yoke portion of the stator portion.
 13. The electromagnetic machine of claim 12, wherein the bolt shafts and at least one bolt end being insulated from the lamination stack and frame structures by a plurality of insulator tubes and insulator rings to avoid induced electrical currents and resulting losses and heating.
 14. The electromagnetic machine of claim 1, also comprising an air cavity between outer stator windings and an air cavity between the inner stator windings for air-cooling the windings.
 15. A gas turbine engine comprising; a high pressure turbine and a low pressure turbine disposed in the gas turbine engine in serial flow communication, and an electrical machine arranged coaxially with the high pressure turbine and the low pressure turbine; a shaft of the high pressure turbine and a shaft of the low pressure turbine concurrently rotatable in the same or in opposite directions, and controllably operable at matching velocity or at separate and distinct velocities; the electrical machine comprising: a fixed stator element, a first rotor element and a second rotor element, the first and second rotor elements independently rotatable with respect to the stator element; the first rotor element mechanically connected with the shaft of the high pressure turbine, and the second rotor element being mechanically connected with the shaft of the low pressure turbine; the stator element having an inner multiple-phase winding set and an outer multiple-phase winding set wound thereon, each of the winding sets configured to generate separate power outputs or to receive a separate excitation power source, the inner and outer winding sets being mutually exclusive; a plurality of outer permanent magnets disposed on an inner surface of the outer rotor element and a plurality of inner permanent magnets disposed on an outer surface of the inner rotor element; an outer air gap defined between the outer surface of the stator portion and the outer permanent magnets, and an inner air gap defined between the inner surface of the stator portion and the inner permanent magnets; wherein each of the first and second rotor elements are configured to generate electrical power through electromagnetic coupling with the stator element when driven by the associated high or low pressure turbine shaft, or to electrically drive the associated high or low pressure turbine shaft when excited by an external electrical power source. 